Lined, collapsible container structure with automatically actuated end closure means



' Nov; 19, 1968 w. WHITAKER ETAL LINED. COLLAPSIBLE CONTAINER STRUCTURE WITH AUTOMATICALLY ACTUATED END CLOSURE MEANS Filed May 31, 1966 5 Sheets-Sheet l INVENTORS WILLIAM C. WHITAKER EDWARD H. KANE THEI ATTORNEYS 1953 w. c. WHITAKER ETAL 3,

LINED. COLLAPSIBLE CONTAINER STRUCTURE WITH AUTOMATICALLY ACTUATED END CLOSURE MEANS Filed May 31, 1966 I 5 Sheets-Sheet 2 THEIR ATTORNEYS iNVENTORS Nov. 19, 1968 W. C. WHITAKER ETAL LINED, COLLAPSIBLE CONTAINER STRUCTURE WITH AUTOMATICALLY Filed May :1, i966 ACTUATED END CLOSURE MEANS 3 Sheets-Sheet 5 I Ii 74 Z3 46 44 mvE'moRs 70 WILLIAM c. WHITAKER 48 EDWARD H. KANE 60 BY 34 )Qg THEIR ATTORNEYS United States Patent LINED, COLLAPSIBLE CONTAINER STRUCTURE WITH AUTOMATICALLY ACTUATED END CLO- SURE MEANS William C. Whitaker, Chesterfield County, and Edward H. Kane, Henrico County, Va., assignors to Reynolds Metals Company, Richmond, Va., a corporation of Delaware Filed May 31, 1966, Ser. No. 553,842 7 Claims. (Cl. 229-14) ABSTRACT OF THE DISCLOSURE This disclosure relates to a fluid-tight container means which is readily collapsible for storage and handling and expandible for use and comprises an outer structural carton and an inner sleeve liner which has a pair of opposed walls fastened against associated walls of the car ton. One end of the sleeve liner is fin-sealed closed and bonded to the tenminal inner end surface of a comparatively long closure flap of the carton. A short extension flap provided in a wall of the carton arranged opposite the closure flap, upon being folded inwardly, automatically starts the inward folding action of the closure flap to enable easy assembly of the container means and conceal and protect the inner sleeve liner beneath such closure flap.

This invention pertains to collapsible container means and more particularly to improved fluid-tight collapsible container means and to an improved method for making such fluid-tight container means.

Currently available containers having liquid-tight liners therein are generally quite expensive being constructed using comparatively expensive materials and complicated manufacturing equipment. In addition, such currently available containers which are also collapsible are difficult to assemble further increasing operating costs associated with their use.

Accordingly, it is a feature of this invention to provide an improved collapsible fluid-tight container means of simple and economical construction.

Another feature of this invention is to provide such container means which may be supplied to a user thereof in the flat form, such container means having outer structural wall means supporting tubular sleeve liner means therewithin with one end of such sleeve liner means being presealed.

Another feature of this invention is to provide improved container means of the character mentioned in which the sleeve liner means carried within outer structural wall means is bonded thereto while such wall means and sleeve means are in a flattened form.

Another feature of this invention is to provide an improved collapsible container means having a fluid-tight sleeve liner means therewithin in which one end wall means thereof is simply and efiiciently formed and in which extension flap means comprising such end wall means initiates the closing action of closure flap means defining the outside surface of such end wall means.

Another feature of this invention is to provide such a container means having fluid-tight sleeve liner means therewithin which employs a fin seal for increased economy, such sleeve liner means being bonded adjoining its fin seal to closure flap means extending from outer supporting wall means of such container means.

Another feature of this invention is to provide improved container means in which the sealing arrangement provided at one end wall means defines pouring spout means having an optimum geometric configuration.

Another feature of this invention is to provide an improved method for making fluid-tight collapsible con- 3,411,691 Patented Nov. 19, 1968 ice tainer means economically and rapidly with a minimum of special equipment.

Another feature of this invention is to provide an improved method for making collapsible fluid-tight container means in which the outer structural wall means thereof and the inner sleeve liner means are bonded together in the flat form for increased manufacturing economy.

Another feature of this invention is to provide an improved method for making collapsible fluid-tight container means in which such sleeve liner means has a fin seal made in one end thereof which is simultaneously bonded to closure flap means of such container means.

Another feature of this invention is to provide an improved method for making such container means in which extension flap means provided in side wall means thereof cooperate with sleeve liner means carried therewithin to provide efficient and simple closure at one end means thereof in which the extension flap means automatically initiates the closing action of closure flap means defining the outside surface means of such one end means.

Therefore, it is an object of this invention to provide an improved collapsible fluid-tight container means and an improved method for making such container means having one or moreof the novel features of this invention as set forth above or hereinafter shown or described.

Another object of this invention is to provide improved blanks for making such container means or the like.

Other objects, uses, and advantages of this invention are apparent from a reading of this description which proceeds with reference to the accompanying drawings forming a part thereof and wherein:

FIGURE 1 is a perspective view of the structural outer wall means of the exemplary container means of this invention with extension flap means provided therein shown in their extended positions and showing score means in oppositely arranged side wall means thereof.

FIGURE 2 is a perspective view of sleeve liner means used with the container means illustrated in FIGURE 1, particularly illustrating score means in oppositely arranged side wall means thereof which cooperate with corresponding score means in the outer wall means, shown in FIGURE 1, to enable collapsing of the assembly with the liner means inserted therewithin.

FIGURE 3 is a perspective view of the liner means of FIGURE 2 inserted within structural outer wall means of FIGURE 1 showing the assembly in a flattened form and showing a fin :seal made in one terminal end of the sleeve liner and such terminal end bonded to the inside surface of closure flap means provided in the structural outer wall means.

FIGURE 4 is a perspective view showing the liner and outer structural wall means of FIGURE 3 in its expanded position.

FIGURE 5 is a side view of the container means with a portion thereof broken away illustrating triangular extension fiap means thereof partially folded inwardly and showing the action of a comparatively short rectangular top flap means which initiates the closing motion of the outer closure flap means.

FIGURE 6 is a sectional view on the line 66 of FIGURE 5.

FIGURE 7 is a side view of the container means as illustrated in FIGURE 5 showing the closure flap means in its fully closed position and fastened to such container means.

FIGURE 8 is a view looking inside the container means as illustrated in FIGURE 7.

FIGURE 9 is a plan view of the blank used to make the outer structural wall means of FIGURE 1.

FIGURE 10 is a plan view of the blank used to make the inner sleeve liner of FIGURE 2.

While the various features of this invention are hereinafter illustrated and described as being particularly adaptable for providing a sealed container capable of holding fluid products such as liquids and the like, it is to be understood that the various features of this invention can be utilized singly or in any combination thereof to provide container means for other articles as desired and to provide fluid-tight container means affording unlimited protection against either fluid loss or gain, for example, moisture gain.

Therefore, this invention is not to be limited to only the embodiments illustrated in the drawings because the drawings are merely utilized to illustrate one of the wide variety of uses of this invention.

In the exemplary embodiment of this invention illustrated in FIGURES 1-10 an improved container means or container is illustrated, as well as the improved container blanks, in FIGURES 9 and 10, for making wall means of such container. Container 20 in this example is adapted for containing a liquid product therewithin.

As particularly shown in FIGURES 1, 2 and 4, container 20 has structural outer wall means or an outer carton 21 and tubular sleeve liner means illustrated as a tubular sleeve 22 adapted for insertion therewithin. Sleeve 22 has one end sealed closed preferably by use of a fin seal as illustrated at 23 and such end is bonded to closure flap means shown as a closure flap 24 extending from first wall means, shown as outer wall 25, defining the outer surface of one end means or end wall 26 of container 20. Means is provided in end wall 26 which cooperates with sleeve 22 and automatically initiates the closing motion or action of fiap 24 as will be described later in detail.

Carton 21 has second wall means shown as wall 27 arranged opposite wall and a pair of oppositely arranged wall means illustrated as side wall means or side walls 28 and 29 each having score means therein designated respectively by the numerals 30 and 31. Score means 30 and 31 are centrally located and enable their associated side walls to be collapsed inwardly thereabout to form bellows or accordion construction for carton 21 in its flattened form. Walls 25, 27, 28 and 29 form structural outer side wall means of generally rectangular outline upon being suitably fastened together.

The tubular sleeve liner 22 is preferably rectangular in outline, as illustrated in FIGURE 2, for cooperation within the rectangular outline carton 21 described above. Sleeve 22 has opposed pairs of walls with one pair being designated by the numerals 35 and 36 and the other pair designated by the numerals 37 and 38. Sleeve 22 in this example is preferably formed using a porous outer paper 39 forming the outer surface thereof and a metallic foil 40 defining the inside surface. Paper 39 is suitably adhesively fastened to foil 40 preferably using a microcrystalline wax sandwiched therebetween.

Although in this example of the invention a microcrystalline wax is used to fasten porous paper 39 to foil 40 to form sleeve 22, it will be appreciated that other suitable materials, for example, glue or a heat-scalable plastic material could be used to accomplish the fastening action. In addition, the paper used may be either porous 0r non-porous.

Centrally located score line 41 and 42 are provided in oppositely arranged walls 37 and 38 of sleeve 22. It will be apparent that upon inserting liner 22 within the carton 21, walls 37 and 38 lie respectively within walls 28 and 29 of the car-ton and score lines 41 and 42 cooperate respectively with score lines 30 and 31 thereof enabling carton 21 with liner 22 therewithin to be collapsed inwardly about their associated score lines. FIGURE 3 illustrates liner 22 and carton 21 in their collapsed or flattened form.

In this exemplary embodiment of the invention wherein microcrystalline wax is provided between paper 39 and foil 40, liner 22 is inserted within carton 21, collapsed to the flat form illustrated, and bonded to such carton while in such fiat form. The bonding technique is more particularly described in United States Patent No. 3,095,134. Basically the bonding action is achieved by heating the flattened container assembly in any suitable way. For example, electrical induction heating has been used very satisfactorily to provide high speed bonding of containers during high volume production. The heating action causes the microcrystalline adhesive wax which is sandwiched between paper 39 and foil 40 of sleeve 22 to exude through the paper surface 39 which is in contact with the inside surface of carton 21 and bond sleeve 22 within carton 21. Of course, in those applications where microcrystalline wax is not used liner 22 may be glued in position, or if such liner is made of heat sealable outer surface means, liner 22 may be heat sealed in position as desired.

Wall 25 has flap 24 extending from a score line 43 at one terminal end thereof, see FIGURE 1. Closure flap 24 is a comparatively long flap being generally rectangular in outline and is longer than any of the other extension flaps to be presented described. Flap 24 defines the outside surface of wall 26 as previously mentioned.

.Wall 27 has an extension flap which is also of rectangular outline and is a comparatively short flap designated by the numeral 44 and extending from a score line 45 provided in one terminal end of wall 27. Score line 45 is arranged generally opposite and parallel to score line 43.

A pair of triangular extension flap means or triangular extension flaps 46 and 47 extend beyond score lines 50 and 51 defining one terminal edge of walls 28 and 29 respectively. Score lines 50 and 51 adjoin score lines 43 and 45 at their corresponding opposite ends. Triangular extension flaps 46 and 47 cooperate with the comparatively short rectangular flap 44 and the long closure flap 24 to define end wall 26 of container 20.

As previously mentioned sleeve liner 22 is preferably bonded within its associated carton 21 in the flat form or configuration illustrated in FIGURE 3. A seal is preferably provided in one end of sleeve 22 at the time of such flat bonding. However, it will be appreciated that such seal may be made prior to insertion within carton 21. The seal provided is shown as a fin seal and is preferably made simultaneously with the bonding of the associated end of liner .22 to closure flap 24.

The fin seal in this exemplary illustration of the invention is made by forming a plurality of minute perforations in the foil adiacent the terminal end to be sealed. With the sleeve liner of FIGURE 2 collapsed as shown in FIGURE 3, and with heating of the end to be sealed the sealing means such as the heated microcrystalline adhesive wax previously mentioned seeps through the perforations in the foil and provides the fin seal shown at 23. It will be appreciated that liner 22 can be formed from a single fiat sheet by similarly sealing along a side edge thereof parallel, for example, to score lines 41 and 42.

In those constructions using glue or heat scalable plastic materials to make sleeve 22 it will be appreciated that the fin seal shown at 23 could be provided by suitable gluing or heat sealing of sleeve 22 to carton 21.

The collapsed container 20 with fin seal 23 made in one end of sleeve liner 22 bonded therewithin is shipped to a user thereof in its collapsed or flattened condition. This of course assures that such user requires a minimum of storage space for each container. In addition, a large number of such containers are easily transported in a comparatively small package.

The assembly of container 20 from the collapsed form of FIGURE 3 is accomplished in an efficient and simple manner and preferably employs the use of vacuum means such as suction cups. The suction cups act upon walls 25 and 27 to pull such walls apart and thereby extend walls 23 and 29.

With walls 28 and 29 in their normally extended positions, their respective triangular flaps 46 and 47 are folded inwardly. As will be apparent from FIGURES 4 and 5 of the drawings, the apex of each triangular flap 46 and 47 engages liner 22 in the area immediately adjoining its respective score line 41 and 42. With triangular flaps 46 and 47 partially folded inwardly the comparatively shorter flap 44 is folded downwardly further shoving flaps 46 and 47 inwardly. This inward closing action of flap 44 causes such flap to engage the outside top surface of sleeve 22. Because sleeve 22 is fastened to the terminal inner end surface of flap 24, this closing motion of flap 44 engaging sleeve 22 and urging flaps 46 and 47 inwardly automatically initiates the closing action of closure flap 24. The automatic closing action will be apparent particularly from FIGURE 5 of the drawings.

Closure flap 24 has adhesive means applied to its inside surface adjacent its terminal end and illustrated generally at 48. The adhesive means may be any suitable adhesive and is preferably a quick drying glue or the like. The adhesive means may be applied at the time of sealing or in certain applications it may be desirable to provide sealing means applied at the time of forming carton 21, such as an adhesive which seals upon application of pressure thereagainst. As flap 24 is folded into the position illustrated in FIGURE 7, the adhesive means seals flap 24 in position to define the outside surface of end wall 26.

With end wall 26 sealed in position as described above container 20 is ready for use and is discharged from its assembly area to standard filling equipment. In this example of the invention, container 20 is ready for placement of a fluid product therewithin. From the standard filling equipment container 20 is transferred to standard closing equipment for sealing extension flap means provided at the opposite end of container 20 and defining an opposite end wall 26A for container 20.

The arrangement of sleeve 22 within container 20 at the terminal end 26 is illustrated particularly in FIGURE 8. It will be appreciated that by merely unfastening flap 24 and tearing sleeve 22 adjacent fin seal 23 it is possible to provide a pouring spout for container 20 which has an optimum pouring configuration because the side walls of sleeve 22 converge. Such optimum pouring configuration is preferably produced by separating walls 35 and 36 of sleeve 22 along the central portion of fin seal 23 with sleeve 22 bonded to flap 24 immediately under fin seal 23.

The manner of sealing sleeve linear 22 and bonding such-liner within carton 21 also provides a structural arrangement of improved structural strength and fluidtight performance. For example, a container 20 full of water has satisfactorily withstood severe loading imposed by vibration testing without damage thereto.

In this example of the invention sleeve 22 preferably has metallic foil 40 laminated on the inside surface thereof. It will be appreciated that metallic foil or the like may be applied to either of both sides of sleeve 22 or to either or both sides of carton 21 as dictated by the requirements of the product to be carried within container 20 and the individual requirements of the user of such container.

Carton 21 can be formed in any suitable manner and made from any suitable foldable material. It is preferably formed from the container blank 60, illustrated in FIG- URE 9. Blank 60 is made of cardboard or the like having a side such as the exposed surface thereof laminated with metallic foil, such as aluminum-containing metallic foil, or the like, suitably colored, embossed, imprinted, or remaining plain, as desired.

Blank 60 is suitably cut and scored to define a plurality of six exterior side walls which in this example of the invention are suitably fastened in the shape of parallelepiped.

Parallel spaced apart score lines 61, 62, 63 and 64 are provided in blank 60 and define one side edge of foldably connected walls 27, 28, 25, and 29 respectively. An extension flap 65 extends beyond score line 64 defining one edge of wall 29 and upon being suitably fastened, as

6 by glue, to wall 27 forms the elongated tubular structure shown in FIGURE 1 of the drawings.

As previously described rectangular flaps 24 and 44 extend respectively beyond score lines 43 and 45 defining one edge of their respective walls 25 and 27. Similarly triangular extension flaps 46 and 47 extend respectively beyond score lines 50 and 51 defining one edge of their respective walls 28 and 29. Thus, upon assembling carton 21 from blank 60 flaps 24, 44, 46, and 47 define the outer structural portion of end wall 26.

A score line is provided in blank 60 extending thereacross normal to the terminal ends of score lines 61-64. A plurality of extension ilaps 71, 72, 73, and 74 is provided extending respectively beyond the associated portion of score line 70 defining the opposite end edge of walls 27, 28, 25, and 29. Flaps 71-74 are suitably fastened together, as by glue or the like, after filling assembled container 20 to define the outer structural portion of wall 26A.

The sleeve liner 22 of this example of the invention is made from a rectangular blank 80, see FIGURE 10. Blank may be made of any foldable material which is impervious to fluid flow therethrough. In this example, blank 80 is made of metal foil 40 adhesively fastened to a paper sheet 39 by the adhesive microcrystalline Wax designated by the numeral 86 is FIGURE 2 of the drawings and as mentioned previously.

Blank 80 is suitably cut to form a rectangular sheet that has a series of parallel spaced apart score lines 81, 82, 83, and 84 extending thereacross. As will be apparent from FIGURE 10, one side edge of each wall 37, 35, and 38 is defined by score lines 81, 82, and '83- respectively. Score lines 41 and 42 are provided essentially bisecting the surface areas of walls 37 and 38 respectively for reasons as previously described.

Wall 36 is formed upon folding blank 80 about score lines 81-84 and overlapping the terminal opposite side edge portions of such blank designated by the numerals 36A and 36B and extending respectively beyond score lines 81 and 84. Portion 36B has suitable adhesive means applied along its terminal end in an elongated adhesive strip designated by the numeral 85.

Blank 80 is folded about score lines 81-84 so that the metal foil 40 forms the inside surface of liner 22. Adhesive 85 assures a tight seal while containing fluid within liner 22.

While the sleeve liner 22 in this preferred embodiment is made from rectangular blank 80 as described above, it will be appreciated that such sleeve may be extruded in the desired tubular form and suitably fastened within carton 21 and to the outer end portion of closure flap 24.

Terms such as side wall, end wall, top, end, etc., have been used in this disclosure for ease of description and to better explain the example of this invention as presented in the drawings and such terms should not be considered as limiting the scope of this invention in any way.

Thus, it is seen that improved fluid-tight container means has been provided which is collapsible prior to use and which employs unique means enabling rapid and effective sealing as well as simple opening thereof.

Further, an improved method has been provided for making such collapsible fluid-tight container means.

While the form of the invention now preferred has been disclosed as required by statute, other forms may be used, all coming within the scope of the claimed subject matter which follows:

1. Collapsible container means comprising, structural outer Wall means including a first wall having a closure flap extending therefrom and a second wall arranged opposite said first wall and having an extension flap extending therefrom and said closure flap and said extension flap each having a substantially rectangular outline with said extension flap having a shorter length than said closure flap and cooperating therewith to define an end wall means for said container means, and tubular sleeve liner means having a pair of oppositively arranged liner walls each fastened against an associated one of said first and second walls and having one end sealed closed and bonded against said closure flap said container means being adapted to be collapsed to a flat form and readily expanded for use by moving said first and second walls outwardly to also simultaneously expand the main portion of said sleeve liner means causing an end portion of each of said pair of oppositely arranged liner walls to converge toward said sealed end to define a sealed pouring spout and upon folding said extension flap inwardly to define said end wall means it engages said sleeve liner means adjacent said sealed end and with further inward movement of said extension flap automatically initiates the closing of said closure flap which forms an outer surface for saidend wall means which fully conceals and protects said sleeve liner means therebeneath, and upon unfasteuing said closure flap and tearing said sleeve liner means adjacent said sealed end said sealed pouring spout is opened to enable an associated product contained within said container means to be poured therethrough.

2. Container means as set forth in claim 1 in which said tubular sleeve liner means has said one end fin-sealed closed and bonded to the terminal inner end portion of said closure flap.

3. Container means as set forth in claim 1 in which said structural outer wall means also includes a pair of oppositely arranged equal width side walls each having a centrally located score line therein enabling said pair of side walls to be easily collapsed inwardly to thereby flatten said container means into a compact area having said equal width.

4. Container means as set forth in claim 3 in which said tubular sleeve liner means has metal foil laminated to a surface thereof thereby providing said container means which is fluid tight.

5. Container means as set forth in claim 1 in which, said structural outer wall means also includes a third wall, a fourth wall, arranged opposite said third wall, each of said third and fourth walls being fastened to associated edges of said first and second walls and initially defining said outer wall means having a rectangular cross-sectional outline, said third and fourth walls each having a triangular extension flap extending therebeyond and each triangular extension flap being free of said tubular sleeve liner means, said tubular sleeve liner means has a rectangular cross-sectional outline corresponding to the cross-sectional outline of said outer wall means, and said extension flaps cooperating with said closure flap to form said end wall means in an efficient manner by first folding each of said triangular extension flaps about its base, causing the apex of each triangular extension flap to engage said sleeve liner means and with said triangular extension flaps partially folded inwardly said extension flap extending from said second wall is then folded against said sleeve liner means to shove said triangular flaps further inwardly and initiate said automatic closing of said closure flap.

6. Container means as set forth in claim 5 in which said third and fourth walls each has centrally located score means extending therealong and bisecting an as sociated triangular extension flap enabling said third and fourth walls each to be collapsed inwardly by folding about its associated score means.

7. Collapsible container means having structural outer wall means and tubular sleeve liner means fastened therewithin, said structural outer wall means being formed from a single sheet of foldable material and comprises a first wall having a closure flap extending therebeyond, a second wall arranged opposite said first wall and having an extension flap extending therebeyond which has a shorter length than said closure flap, third and fourth oppositely arranged walls each having a triangular extension flap extending therebeyond, with said first, second, third, and fourth walls being initially foldably fastened together to define an open ended tubular structure of rectangular sectional outline, a plurality of walls in said tubular sleeve liner means having a rectangular sectional outline corresponding to the rectangular sectional outline of said structural outer wall means, centrally located score means extending along said third and fourth walls and each bisecting an associated triangular extension flap, cooperating centrally located score means in associated walls of said tubular sleeve liner means which associate with said third and fourth Walls, each of said cooperating score means extending along the full length of its wall, said third and fourth walls and said associated walls of said tubular sleeve liner means being adapted to be collapsed inwardly by folding about their associated cooperating score means to thereby flatten said structural outer wall means and said tubular sleeve liner means, and said tubular sleeve liner means having one end which is fin-sealed closed and bonded to the terminal inner end portion of said closure flap, whereby said container is readily expanded for use and upon expanding thereof said extension flaps cooperate with said closure flap to form an end wall means for said container means in an efficient manner by first folding each of said triangular extension flaps about its base followed in folding sequence by said extension flap which extends from said second wall which engages said sleeve liner means and automatically initiates the closing of said closure flap which forms an outer surface for said end wall means.

References Cited UNITED STATES PATENTS 1,775,027 9/1930 Hartmann 229l4 2,089,483 8/1937 .laenicke 229-14 2,170,378 8/1939 Orstrom 229l4 2,177,918 10/1939 Vogt et al. 229l4 2,250,249 7/1941 Bergstein 229l4 2,307,559 1/1943 Angus a 229l4 2,427,858 9/1947 Hogdal 1 22914 2,879,933 3/1959 Bergstein et al. 22941 X 2,959,336 11/1960 Mosse et al. 229l4 2,979,247 4/1961 Pellaton et al. 229l4 3,079,060 2/196'3 Cherrin 229l4 DAVIS T. MOOREHEAD, Primary Examiner. 

